THE NAME OF GOD

HEAT TRANSFER

HEAT EXCHANGERS

PREPARED BY:-

NAME:- FARES NASSER HAITHAM ABDULRAB

REG.NO:- 151003

CLASS :- B3M

SUPERVISED BY :-

MR.SABER RASHAD
What are Heat exchangers ?

Heat exchangers is a mechanical device used to transfer heat between a solid object
and a fluid, or between two or more fluids. The fluids may be separated by a solid
wall to prevent mixing or they may be in direct contact.[1] They are widely used
in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing, sewage
treatment , And liquid cooling system of some PC.

2. What types of Heat Exchanger are available?

There are many different types of heat exchanger available, example the three main
types that are;

 Shell and Tube;

Shell and tube heat exchangers consist of
series of tubes. One set of these tubes
contains the fluid that must be either heated
or cooled. The second fluid runs over the
tubes that are being heated or cooled so that
it can either provide the heat or absorb the
heat required. A set of tubes is called the
tube bundle and can be made up of several
types of tubes: plain, longitudinally finned,
etc. Shell and tube heat exchangers are typically used for high-pressure
applications (with pressures greater than 30 bar and temperatures greater
than 260 °C).[2] This is because the shell and tube heat exchangers are robust
due to their shape.
 Plate Type; Plate Heat Exchangers operate in
very much the same way as a shell and tube heat
exchanger, using a series of stacked plates rather
than tubes. Plate heat exchangers are usually
brazed or gasketed depending on the application
 and fluids being used. Their compact stainless steel construction makes them
an ideal choice for use with refrigerants or in food and beverage processing.
 Air Cooled Air Cooled Heat Exchangers are commonly used in vehicles or other
mobile applications where no permanent
cool water source is available. Most designs
and supplies combination cooling packs (or
combined-coolers) which combine an
engine jacket water cooler, oil cooler and
charge air cooler into a single unit reducing
space requirements and improving
efficiency. Cool air is provided either by a
fan or by air flow caused by the movement of the vehicle.
3.How is a Heat Exchanger is designed?

The design of a heat exchanger addresses mainly three phases

A. The choice of technology

Selection of the optimum technology is linked to:

 The thermal program (Required temperatures, efficiency…)

 The nature of the fluids
 The application
 The constraints of installation and maintenance

B.Thermal design

a. Validation of the thermal program

Once the technological choices made, we will proceed to the design of the heat
exchanger , i.e. determining its power, size and geometry. It is first necessary to
validate the data of the thermal program, with the following 3 formulas:
P: Power (in KW or KCal/h)
T: temperature (in °C)
Q: Flowrate (in
Kg/h) △t:
(Tin –Tout)in °C
Cp: Specific heat (in KWh/Kg/°C)

Example: application for cooling water at a flowrate of 10 m3/h

Thanks to those formulas, the other data can be calculated. Here we have:

i.e.
Tout = 73°C
Total power: 65,000 KCAL/h or 756 KW

b. Calculation of the heating surface

First, LMDT (Logarithmic mean temperature difference) shall be calculated. The

LMDT is the logarithmic average of the temperature differences at each end of the
heat exchanger:
Tin1 : Tin cold
Tin2 : Tin hot
Tout1 : Tout cold
Tout2 : Tout cold

Once LMDT and Power have been calculated, the heat exchanger calculation can be
done as per the following formula:
K: Heat Transfer Coefficient in KW/°C/m2 that is specific to each
type of equipment and given by the manufacturer.
S : Heating area in square meters.

c. Calculation of K and incrustation

The Heat Transfer Coefficient of an heat exchanger is given by :

h1 and h2: Local Heat exchange Coefficients calculated as per the local geometry as
well as dimensionless numbers such as Reynolds (Re), Prandlt (Pr) and Nusselt (Nu).
e: Wall thickness in m
λ: Thermal Conductivity of the wall
in W/°C/m
Rencrustation: Resistance due to the
wall fouling

Getting the Heat Transfer Coefficient (HTC or K) enables to find the heating area and
hence sizing the heat exchanger.

3. Calculation of the heat exchanger pressure drop

A moving fluid undergoes energy losses due to friction on the walls (regular head
loss) or mishaps (singular head losses) such as baffles, for example. This loss of
energy, expressed in pressure drop (△P) must be compensated to allow the fluid to
move.
  Heat exchanger efficiency and effectiveness
We must not confuse efficiency and effectiveness. Indeed, considering no loss by
radiation, therefore the effectiveness of a heat exchanger is equal to 1.
The efficiency (yield) corresponds to the
following formula:

Obtaining a yield of 100% is impossible. The

yield is induced by the needs for power and
temperatures of the client’s application.
Hence in most cases, it is fixed upon request by the client himself.
. What fluids can a Heat Exchanger operate with?

The suitability of a fluid with a heat exchanger will depend on the type of heat
exchanger being used and the materials which are available. Standard Heat
Exchangers are suitable for most fluids including Oil, Water, Water Glycol and Sea
Water. For more corrosive fluids such as chlorinated salt water, refrigerants and
acids other materials such as Stainless Steel and Titanium will need to be used
instead.

. What is a heat exchanger "pass" and how do I know how many passes I need?
A Heat Exchanger Pass refers to the movement of a fluid from one end of the heat
exchanger to the other end. For example, Triple Pass – Fluid travels the length of the heat
exchanger body three times before exiting.

 A greater number of passes increases the amount of heat transfer available, but can also
lead to high pressure loss and high velocity.
 With a full set of operational data, We can select the most efficient heat exchanger
possible whilst working within the pressure loss and velocity limits.
 The number of passes on the primary circuit can also be adjusted to optimize thermal
performance and efficiency by changing the baffle quantity and pitch
Single Pass DOUBLE PASS Triple Pass
4. How to make a heat exchanger more efficient.

Heat exchanger efficiency can be defined in many ways, in terms of thermal

performance there are several key factors to consider;

 Temperature differential - the difference between the hot fluid and coolant is
very important when designing a heat exchanger. The coolant always needs to
be at a lower temperature than the hot fluid. Lower coolant temperatures will
take more heat out of the hot fluid than warmer coolant temperatures same
principle applies to heat exchangers.

 Flow rate - Another important factor is the flows of the fluids in both the
primary and the secondary side of the heat exchanger. A greater flow rate will
increase the capability of the exchanger to transfer the heat, but a greater flow
rate also means greater mass, which can make it more difficult for the energy
to be removed as well as increasing velocity and pressure loss

7. Which industry-specific Heat Exchangers is being Used ?;

Hydraulic and Industrial  Hydraulic Oil Coolers (Shell and Tube)

Equipment  Brazed Plate Heat Exchangers

 Air Cooled Oil Coolers
Marine  Marine Oil Coolers
 Header Tank Heat Exchangers

Food Process Equipment  Stainless Steel Shell and Tube Heat Exchangers
 Brazed Plate Heat Exchangers
Mobile Plant  Air Cooled Heat Exchangers
 Hydraulic Oil Coolers
Power Generation  Exhaust Gas Heat Exchangers
 Manifold Heat Exchangers
 Header Tank Heat Exchangers
 Air Cooled Heat Exchangers

How to increase the lifetime of a Heat Exchanger

Heat exchangers are manufactured from robust materials, have no moving parts and
operate at a variety of different pressures and temperatures, therefore if a heat
exchanger is used in the correct way then there is no reason why it shouldn't be able
to remain operational for many years. To help increase the operational lifetime of a
heat exchanger there are several steps that should be taken;

 Make sure the design data is accurate - If you are sending data to our engineers
for heat exchanger selection, then it is best to make sure that it is as accurate
as possible. Not only will this ensure that your heat exchanger is thermally
efficient but also that it will be able to operate for a long period of time.

 Regular Maintenance and Servicing - All shell and tube heat exchangers are
designed to allow for easy maintenance and servicing. The end caps can be
removed allowing the internal tube bundle to be removed for cleaning.

Refrences :-

1.https://en.wikipedia.org/wiki/Heat_exchanger

2.http://www.explainthatstuff.com/how-heat-exchangers-work.html

3.http://www.thermex.co.uk/news/blog/160-what-is-a-heat-exchanger

4.http://www.barriquand.com/en/news/how-to-design-heat-exchanger